Method of manufacturing molded article including component insert-molded in resin mixed with solid powder

Abstract

The exemplary embodiment provides a method of manufacturing a molded article including a component insert-molded in a molding material mixed with solid powder. The method includes an injecting step of injecting the molding material and the solid powder into a molding die, an agitating step of agitating the molding material and the solid powder within the molding die to disperse the solid powder in the molding material, and an embedding step of pressing and embedding the component into the agitated mixture of the molding material and the solid powder while vibrating at least one of the component and the molding die.

Description

[0001]This application claims priority to Japanese Patent Application No. 2011-169806 filed on Aug. 3, 2011, the entire contents of which are hereby incorporated by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to a method of manufacturing a molded article including a component insert-molded in a resin mixed with solid powder.[0004]2. Description of Related Art[0005]Japanese Patent Application Laid-open No. 2007-136805 describes a method of manufacturing such a molded article. In this method, a molded article is manufactured by agitating a casting material injected into a casting material cup, and injecting the agitated casting material into a casting die from the casting material cup. When the casting material is a molding material to be mixed with solid powder, the molding material and the solid powder mixed at a predetermined mixing ratio is injected into the casting material cup, and agitated so that the solid powder is d...

AI Technical Summary

Benefits of technology

The patent text describes a method to make plastic parts that have a consistent amount of solid powder mixed in them. This results in parts that have low variation in the amount of solid powder. The method is very efficient and can produce a high number of parts with the desired mixing ratio.

Problems solved by technology

However, the above method has a problem in that since the solid powder precipitates in the casting material cup, the mixing ratio of the solid powder deviates from die-to-die.

Further, when the mixing ratio of the solid powder is high, since the viscosity of the agitated mixture of the molding material and the solid powder is high, it becomes difficult to inject the agitated mixture into the casting die from the casting material cup, causing the manufacturing time to be lengthened.

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